Toggle switch



1961 M. ZANICHKQWSKY ETAL 2,972,663

'roccmz SWITCH Filed Feb. 3, 1958 INVENTORS MARTIN ZANICHKOWSKY ANTHONYJ. SCIARINNO AT TORNEY United States Patent TOGGLE SWITCH MartinZanichkowsky, Richmond Hill, and Anthony J.

Sciarinno, Massapequa, N.Y., assignors to Allied Control Company, Inc.,New York, N.Y., a corporation of New York Filed Feb. 3, 1958, Ser. No.712,971

2 Claims. (Cl. ZOO-67) This invention relates to toggle switches and inone of its more specific aspects to a toggle switch of the center-01ftype.

One of the major problems in the design and construction of snap actionor toggle switches, particularly those of the momentary type, is theadjustment of their spring loading to insure prompt and positive action.

Another problem is that of assembling the actuating means toggle linkageand its spring means inside the switch housing. This problem isparticularly pertinent in the case of very small switches of thesub-miniature type. The moving parts within the switch housing usuallyinclude a pivotally mounted member and a spring loaded linkage includingtwo elements loosely joined by a ball and socket connection. It is verydifficult to assemble the loose pieces and then insert them in thecasing of a very small switch, since the parts are only held together bythe housing. It has generally been the practice in the past to stick theloose parts together with a grease and then insert them in the switchhousing. This not a positive procedure and quite frequently has to berepeated several times before a successful assembly can be completed.

The. present invention overcomes the difiiculties experienced in thepast in that it provides a toggle switch wherein the housing is firstsealed with certain parts positioned therein and other parts, includinga rod, are then inserted through a hollow handle which forms part of theswitch actuating means. Our construction permits the elements of theactuating means to be readily aligned and positioned with respect toother parts. Moreover, our invention permits the loading on the springto be readily adjusted from the exterior of the switch, as required.

A toggle switch constructed in accordance with this invention preferablyincludes a housing comprising a base and a cover or casing secured tothe base. The base carries a pair of spaced electrical contacts.Positioned within the housing is a generally U-shaped saddle consistingof a web which is secured to the base and a pair of arms which projectinto the interior of the housing. Each arm has an end groove. Mountedfor rocking movement on the saddle is a rocker unit comprising acruciform member which includes a pair of oppositely projecting firstarms and a pair of oppositely projecting second arms that are normal tothe first arms. Each of the second arms registers with a correspondinggroove in the saddle and each of the first arms is adapted to contact anelectrical contact in response to corresponding rocking movement of therocker unit.

The switch also includes actuating means for effecting rocking movementof the rocker unit in opposite directions to thereby cause a selectedfirst arm to make contact with a corresponding one of the electricalcontacts. The actuating means comprises a tubular handle which ispivotal with respect to the cover and a rod unit slidable in the handleand including an end part that registers with a depression in thecruciform member. Such end 2,972,663 Patented Feb. 21, 1961 partpreferably consists of a hard, wear-resistant insulating material, suchas glass. A helical compression spring is positioned within the handleand normally and yieldingly urges the rod unit toward the rocker unit.

The switch is provided with an adjustable means for varying the loadingon the spring. This means preferably consists of a ball cap having athreaded extension which engages the handle and is spaced from the rodunit. A floating pin is positioned within the confines of the spring andis adapted to hear at its ends against the other end of the rod unit andthe adjustable means to thereby limit compression of the spring in use.The inclusion of the floating pin in the structure prevents damage tothe spring due to abuse and eliminates the possibility of the springacquiring a permanent set due to excessive movement of the hollow handlerelative to the rod unit.

A principal object of this invention is to provide an improved toggleswitch of the miniature and sub-miniature types.

Another object of the invention is to provide a toggle switch which maybe readily assembled.

A further object of the invention is to provide a spring loaded toggleswitch wherein the spring loading may be externally adjusted.

A still further object of the invention is to provide miniature andsub-miniature toggle switches which are simple and compact in design,sturdy and durable in construction, reasonable in manufacturing cost anddependable in operation.

The enumerated objects and other objects, together with the advantagesof this invention, will be readily understood by persons skilled in theart from the following detailed description and the accompanying drawingwhich, respectively, describe and illustrate a preferred toggle switchembodying the invention.

In the drawing, wherein like reference characters denote correspondingparts in the several views:

Fig. 1 is a top plan view of a toggle switch constructed in accordancewith this invention;

Fig. 2 is a view in cross section taken along line 2-2 of Fig. 1;

Fig. 3 is a view in cross section taken along line 3-3 of Fig. 2;

Fig. 4 is a bottom plan view of Fig. 2; and

Fig. 5 is a top plan view of a rocker unit which is also shown in Figs.2 and 3.

The illustrated embodiment of the invention includes a housing 10 whichconsists of a base 11 and a cover or casing 12. Base 11 is made of asuitable electric insulating material and is formed with an outerannular recess which is defined in part by shoulders 13. The basecarries a plurality of external electrical terminals, namely a centralterminal 14 and a pair of end terminals 15 and 16. The terminals 14, 15and 16 are secured to the base by means of corresponding combined rivetsand electrical contacts 14', 15 and 16' which project into the interiorof the housing.

Cover 12 comprises a rectangular tubular member 17 having a plurality oftongues 18. The lower end of tubular member 17 is adapted to registerwith the outer annular recess of the base and bear against shoulders 13,as illustrated in Fig. 2. When the parts are in this relative position,tongues 18 are bent inwardly with respect to the bottom of the base, asshown in Figs. 3 and 4, to thereby firmly secure cover 12 to base 11.Tubular member 17 is provided with a right circular cylindrical tubularextension 19 that is externally threaded, as indicated at 20. A pair ofnuts 21 engage threads 20 and serve to maintain the switch in selectedposition on a panelboard or other support (not shown). The throughopening in extension 19 is defined in part by a downwardly convergentfirst surface 22 and a rounded second surface 23. The juncture of member17 and extension 18 constitutes an inner annular shoulder 24.

The switch of this invention includes a U-shaped saddle 25 which, asbest shown in Figs. 2 and 3, is disposed in a central recess in base 11.Saddle 25 is electrically conductive and consists of a web 26 and a-pairof arms 27 which project into the interior of the housing. Each arm hasan upper end groove 23. Combined rivet and electrical contact 14'extends through web 26 and secures the saddle to the base. This elementalso serves as an electrical connection between the saddle and terminal14.

A rocker unit 30 is mounted for rocking movement on saddle 25. This unitis best shown in Fig. and cornprises a cruciform base or memberconsisting of a first pair of oppositely disposed arms 31 and 32 and asecond pair of oppositely disposed shorter arms 33 which are normal toarms 31 and 32. The cruciform member is made of a suitable electricallyconductive metal and its arms 31 and 32 are provided with electricalcontacts 31 and 32. Contact 31 is aligned and adapted to make contactwith electrical contact while contact 32' is aligned and adapted to makecontact with electrical contact 16' in use, as will be explained furtheralong herein.

Rocker unit has an upstanding boss or block 34 which is integral withthe cruciform member and which is formed with a depression or recess 35.Boss 34 is assymetrical and consists of a relatively thick side A and arelatively thin side B to obtain what is commonly termed in the art amomentary-otf-on switch.

Rocking movement is imparted to the rocker unit by an actuating means 37which includes a tubular handle 38. This handle has an enlarged lowerend portion 39 which is rounded at 40 for contact with rounded surface23 of extension 19 to permit of pivotal movement of the handle withrespect to the cover. Handle 38 carries a cap which consists of aspherical finger grip 41 and a threaded extension 42 which engages a tapin the upper end of the handle. A solid rod 43 is slidable in handle 33and has a spherical head 44 affixed to its lower end. Rod 43 ispreferably made of a suitable metal, such as that available under thetrade mark Kovar. Spherical head 44 is made of glaSs or otherappropriate wear-resistant electrical insulating material which is fusedto the lower end of rod 43. As shown in Figs. 2 and 3, head 44 registerswith depression 35 of the rocker unit.

There is provided spring means for normally and yieldingly urging rod 43downwardly and spherical head 44 into registry with the depression inthe rocker unit. This spring means preferably consists of a helicalcompression spring 45 which is positioned within handle 38 and bears atits ends against the upper end of rod 43 and the free end of capextension 42. Cap 41 and its extension 42 serve as a means for adjustingthe loading on spring 45. A relatively thin pin 46 is positioned withinthe confines of spring 45. This pin is in the nature of a floating pinfor the reason that its shorter than the distance between the lower endof extension 42 and the upper end of rod 43. This pin, as stated earlierherein, prevents damage to the spring and prevents its acquiring apermanent set in use.

In assembling the switch, handle 38 is inserted in tubular cover member19 and rocker unit 30 is mounted on saddle 25. The entire base assemblyis inserted in cover member 17 with rod 43 projecting into the handleand its spherical head 44 registering with depression 35 of the rockerunit. The base is then affixed to the cover by bending tongues 18inwardly, as earlier described. The base may, if desired, be cemented orotherwise sealed to cover member 17 to provide a fluid tight fittherewith.

Spring 45 is next inserted in the handle from the top and pin 46 isinserted in the spring. The adjustable cap is then applied to the upperend of the handle by means of its threaded extension 42. The cap isturned relative 4 to the handle, as required, to obtain the desiredloading on the spring.

For the purpose of outlining the operation of the illus trated form ofthe invention, it is assumed that the switch has been assembled and thatits parts are in the relative position shown in the drawing. With theparts so arranged, the switch is in center oil position since electricalcontacts 31 and 32' of the rocker unit are out of contact withelectrical contacts 15 and 16, respectively, When handle 38 is pivotedin a clockwise direction relative to the housing, as viewed in Fig. 2,spherical head 44 cooperates with the boss 34 to tilt the rocker unit ina counterclockwise direction relative to saddle 25 to etfect contact ofelectrical contact 31' with electrical contact 15'. This completes theelectrical connection between terminals 14 and 15. Due to theconfiguration of portion A of the boss, such contact is maintained onlyso long as the handle is held in its extreme clockwise pivotal position.Upon release of the handle, the parts antomatically return to theillustrated or off position. Thus the contact between contact elements31' and 15' is momentary.

When the handle is pivoted in a counterclockwise direction relative tothe housing, rod head 44 rides along part B of the rocker unit boss andslightly beyond depression 35. This effects contact between electricalcontacts 32 and 16. Due to the configuration of boss part B, suchcontact continues after the handle is released. The switch is now in onposition and forms electrical connection between terminals 14 and 16.The switch may be reactuated to oif position by returning handle 38 tothe illustrated position (Fig. 2).

The parts are so constructed and arranged that pivotal movement oftheractuating means relative to the housing is limited by engagement ofrod 43 or its spherical head 44 with the shoulder 24 of the cover. Thisprevents excessive movement of head 44 with respect to either of bossportions A or B.

For an on-off-on switch, boss 34 would be symmetrical and both sidesthereof would correspond to part B. For a momentary-ofi-momentaryswitch, boss 34 would be symmetrical and both sides would correspond topart A. In other words, by selecting proper configurations of boss 34,three operatively difierent types of switches may be obtained.

The herein disclosed switch is a single pole toggle switch. It will beapparent that multiple-pole switches, such as double and triple poleswitches, may be constructed in the same manner as the illustratedswitch.

It will be apparent from the foregoing that the present inventionprovides a simple, positive, inexpensive toggle switch and an economicalmethod of assembling the same. The invention also provides convenientmeans for adjusting the spring loading externally, as required. This isvery desirable as the characteristics of the spring will undoubtedly beeffected by aging. The spring characteristics may also be somewhateifected by variations in temperature and humidity conditions. A rubberboot may be placed over the handle to provide a moistureproof seal forthe switch.

The present invention is particularly advantageous for the constructionof very small switches of the subminiature type due to the fact that theparts may be readily assembled. Switches of this invention have beenconstructed with a larger base dimension of less than half an inch andother dimensions proportionally small. Hence, by the practice of thisinvention, very small switches can be constructed which have the samecurrent carrying capacities and voltage ratings as much larger switches,thereby effecting substantial savings in materials and requiring lessspace on a control panel than conventional switches. This is a veryimportant feature in respect to various types of equipment, such ascomputers, where it is necessary to mount a great number of switcheswithin convenient reach of a single operator.

From the foregoing, it is believed that the objects, advantages,construction and operation of our present invention will be readilycomprehended by persons skilled in the art, without further description.Although the invention has been herein shown and described in a simpleand practicable form, it is recognized that certain parts thereof arerepresentative of other parts which may be used in substantially thesame manner to accomplish substantially the same results. Therefore, itis to be understood that the invention is not to be limited to the exactdetails described herein, but is to be accorded the full scope andprotection of the appended claims.

We claim:

1. In a toggle switch, a housing comprising a base and a cover securedto the base, a pair of spaced electrical contacts carried by the base, arocker unit mounted for rocking movement within the housing and adaptedto contact said electrical contacts separately, and actuating means foreffecting rocking movement of the rocker unit in opposite directions tothereby cause the same to make contact with a selected one of theelectrical contacts, said actuating means comprising a tubular handlepivotal with respect to the cover, a rod unit slidable in the handle andbearing at one end against the rocker unit, spring Within the handle andnormally and yieldingly urging the rod unit toward the rocker unit,adjustable means carried by the handle and spaced from the rod unit forvarying the loading on the spring and a floating pin within the confinesof the spring and adapted to bear at its ends against the other end ofthe rod unit and the adjustable'means to limit the loading on the springin use.

2. In a toggle switch, a housing comprising a base and a cover securedto the base, a pair of spaced electrical contacts carried by the base, asaddle comprising a web secured to the base and a pair of arms whichproject into the housing, each arm having an end groove, a rocker unitmounted for rocking movement on the saddle, said rocker unit comprisinga cruciform member including a pair of oppositely projecting first armsand a pair of oppositely projecting second arms that are generallynormal to the first arms, each of the second arms registering with acorresponding groove in the saddle, each of the first arms being adaptedto contact an electrical contact in response to corresponding rockingmovement of the rocker unit, said cruciform member having a depressionformed in the part thereof that is intermediate the arms of each pair ofarms, and actuating means for effecting rocking movement of the rockerunit in opposite directions to thereby cause a selected first arm tomake contact with a corresponding one of the electrical contacts, saidactuating means comprising a tubular handle pivotal with respect to thecover, a rod unit slidable in the handle and including an end part thatregisters with the depression in the cruciform member, said rod end partcomprising a hard, wear-resistant insulating material, such as glass, ahelical compression spring within the handle and normally and yieldinglyurging the rod unit toward the rocker unit, adjustable means carried bythe handle and spaced from the rod unit for varying the loading on thespring and a floating pin within the confines of the spring and adaptedto bear at its ends against the other end of the rod unit and theadjustable means to limit compression of the spring in use.

References Cited in the file of this patent UNITED STATES PATENTS1,666,338 Meuer Apr. 17, 1928 1,677,710 Daniker July 17, 1928 1,694,928Rider Dec. 11, 1928 1,922,696 Hardage Aug. 15, 1933 2,027,538 KriegerJan. 14, 1936 2,432,647 Batcheller Dec. 16, 1947 2,797,275 Seeger June25, 1957 2,808,482 Zanichkowsky Oct. 1, 1957 2,824,189 Zimmer Feb. 18,1958

